general contracting

All piping materials upon arrival of MTC [Mill Test Certificate] shall be checked against the heat number of Pipe. Heat number of Pipe shall be marked [high­ lighted] by using marker. And proper color coding shall be done immediately upon unload. Heat numbers shall be punched on pipe. Each and every pipes and fittings shall be checked for physical damage, damage on edges and verify by using Vernier caliper the schedule of the pipe and ovality of the pipe. Rejected pipes shall be quarantined, NCR shall be prepared and send to vendor and client. Positive Material Identification has to be carried out for Piping materials as per requirement of Project specification.

Piping Isometric drawings shall be sorted as per continuation draw­ ings, Spooling and weld mapping shall be prepared. Required shop drawings shall be stamped and issued for fabrication, proper control of production shall be recorded every day.Completed fit-up spools, isometric drawings shall be highlighted. After fit-up inspec­ tion spools shall be sent for fabrication welding.

Most of important stage of piping fabrication is welding and qualified welder, WPS. Welder qualification shall be carried out by using qualified welding inspector, prior to offer for welder qualification welder has to be trained as per WPS to be used in produc­ tion, Mitigation of welding defects shall be explained to a welder. Proper qualification booth shall be prepared for mass welder qualification. Welders shall be qualified for dif­ ferent piping Materials grade, Thickness range, Diameter range, Welding process, Weld­ ing position. Dissimilar welding if required and multiple welding process. After welder Qualification, welder shall be issued a card and copy of the card shall be taken in record in QC department, and copy shall be maintained in Electrode issuance booth.

Weld management procedure shall be prepared and implemented at site. Required WPS- welding procedure Specification as per section IX shall be prepared and posted at welding area. [For eg: CS/CS welding works - CS WPS shall be posted near welding works so that welder can read and apply the required current and weaving]. The effective imple­ mentation of weld management will give the best result and reduce the rejection of welding.

Welder mindset, Welder training, Weather condition, frequent breaks during welding, Start and stop, pre-heating, interpass cleaning, use of portable oven, proper grounding, proper tools, fit-up, Welding booth. Baking and re-baking.

With reference to the requirement of standard and specification percentage of Destruc­ tive and Non-Destructive Testing shall be decided. RT/UT/MPI and Hardness Testing, all fabrication completed spools after visual check send for NOT Testing.Weld Joints marked and identified for Testing. NDT accepted spools transferred to Sandblasting and painting. After the painting inspection spools delivered to site. Proper Tag to be fixed.

Prior to Installation of piping, pipe rack handover documents shall be received from Structural contractor. Priority shall be given to full length pipes shall be laid on rack as per General Arrangement drawings.

All full-length pipe shall be lifted and pipe support shall be installed and proper Level and alignment shall be maintained. Fabricated spools shall be connected and Field joints shall be welded and subjected to inspection and Testing.

After completion of piping as per Isometric drawing, complete line shall be verified against ISOMETRIC/GA/Pipe supports. Completed lines shall be subjected to Hydro test­ ing/Pneumatic Testing. All lnline instruments shall be removed prior to Testing. After completion of successful testing, all instruments and valves reinstated and bolt torque­ ing shall be performed.

Final Paint touch up works shall be carried out. And color bands shall be printed and permanent labeling shall be printed on Pipe with Direction of flow.

Prior to installation following documents shall be prepared

• Approved Rigging Plan
• Site verification for position of crane and trailer and Equipment access to the erection location.
• Required Safety permits
• Certification of crane and lifting gears and Rigging team and operators.
• Approved Spreader beams shall be arranged if required.
• Above 40Ton Rigger level #1shall be carried out the rigging works.

As per rigging plan Equipment shall be transported to site.Prior to lift Bottom of Base units shall be cleaned. Center points of the column or vessels shall be identified and marked.Erection of static equipment shall be carried out as per rigging plan.Orienta­ tion of Equipment shall be measured as per General arrangement drawing. Straightness shall be checked by using theodolite or plumb.

Multiple reference shall be taken while check the straightness.Since nozzle flange shall be deviated due to welding.

Upon completion of alignment anchor bolt nuts shall be secured for all bolts, and double nuts shall be snug tightened. Required Alignment inspections shall be carried out and documents shall be prepared and get approved from client.

Grouting materials approval shall be taken prior to use, after completion of final inspection of Columns, Base plates shall be offered for Grouting, using compressor air blow foundation surface and verify the clean and oil free, rafted sur­ face, Formworks shall be prepared and soaked 24hrs prior to grouting. Prior to grout foundation surface shall be checked again, Grout mix shall be prepared and poured as per standard specification. Grout cubes samples shall be prepared send for testing.

Prior to installation following documents shall be prepared Approved Rigging Plan

• Site verification for position of crane and trailer and Equipment access to the erection location.
• Required Safety permits.
• Certification of crane and lifting gears and Rigging team and operators.
• Approved Spreader beams shall be arranged if required.
• Above 40Ton Rigger level #1shall be carried out the rigging works.

As per rigging plan rotary equipment shall be transported to site. Prior to lift Bottom of Base units shall be cleaned.Center points of the column or vessels shall be identified and marked. Erection of rotary equipment shall be carried out as per rigging plan.Orientation of Equipment shall be measured as per General arrangement drawing. Base Alignment shall be carried out while crane holding the equipment. After completion of base setting, machine shall be lowered and anchor bolts/nuts shall be secured.

Base Alignment: precision base alignment shall be carried out as per APl610/680 using Master level with least count [-/+ 0.02mm]. All shims installed as per standard. Soft foot shall be checked by using dial indicator. Elevation check from datum line to the center of shaft, longitudinal Co-ordinates to nearest foundation center parallelness, Grouting space should be kept minimum 25mm.

Face and Rim Alignment Method, Reverse Alignment or Laser Alignment.

Static Equipment ground assembly and Installation and Alignment works Rotary Equipment Installation and Alignment works, Equipment loading and unloading storing and preservation.

Removal and replacement of the existing fence works, Installation testing & Commis­ sioning for new antipersonnel fence reinstatement. Installation of Anti Vehicle Barriers (ROSS CRASH RATED FENCE) works

Excavation,back filling & Form wood works, Lean Concrete works.Installation of Ducting & Sub Ducting works.Installation of street light concrete Poles.

Conduit works for lighting and lightening works, power cables.Cable tray fabrication and erection with bonding jumpers and final Inspections.

Installation of Lighting poles, Conduits, fittings, laying wiring and termination and loop checking and testing and energisation.

Cable Testing [Meggerng], Cable laying, Dressing, Cable numbering and Termination and Continuity check, and Energisation.

Laying of Ground cables, Testing and Cad welding and Anode Installation and Testing of Grid.